Automated condensate drain line cleaning system, method, and kit

ABSTRACT

Automated condensate drain line cleaning apparatus are disclosed. In one aspect, an apparatus may include a controller, a fluid supply line, and at least one fluid flow regulation device. The at least one fluid flow regulation device may be electrically coupled with the controller to receive at least one control signal from the controller. The at least one fluid flow regulation device may cause a fluid to flow into a condensate drain line through the fluid supply line responsive to the at least one control signal. Other apparatus as well as methods and kits are also disclosed.

BACKGROUND

1. Field

Embodiments of the invention relate to air conditioning systems. Inparticular, embodiments of the invention relate to systems, methods, andkits to clean condensate drain lines of air conditioning systems.

2. Background Information

Air conditioning systems are widely utilized in homes and businessesthroughout the world. The air conditioning systems, or air conditionersfor short, are used to cool air in order to provide a cool working orliving environment.

By way of example, an air conditioner may have an evaporator orevaporator coils that are used to cool the air. In cooling the air,humidity or water vapor in the air may condense on the relatively coolerevaporator coils. This may produce liquid water known as condensation.Generally, the greater the humidity, the greater the amount ofcondensation produced.

The air conditioner typically includes a primary condensate drain pansituated below the evaporator coils to collect the condensation. Whenthe air conditioner is operating, condensation may form on theevaporator coils, fall from the evaporator coils into the primarycondensate drain pan, and accumulate in the condensate drain pan.

The air conditioner typically also includes a condensate drain line. Thecondensate drain line may be used to drain the condensate from theprimary condensate drain pan to a suitable destination, such as, forexample, a sewer, an outside location, or the like.

One challenge is that the condensate drain line may tend to becomeclogged thereby restricting flow of the condensate from the primarycondensate drain pan. One potential cause is microbial growth. Bacteria,algae, or other microbial matter may tend to grow within the condensatedrain line. Non-microbial debris, such as, for example, dust, dirt,rust, or the like, may also tend to enter the condensate drain line andcontribute to restriction of flow.

Generally, the flow rate of the condensate through the condensate drainline is fairly low. Typically, the flow rate of the condensate isinsufficient to flush or otherwise remove the microbial matter and/ornon-microbial debris from the condensate drain line. Eventually, ifactions are not taken, this growth may tend to close off the condensatedrain line and prevent further flow of condensate from the condensatedrain pan. This may cause the level of condensate in the condensatedrain pan to rise.

Some air conditioners have a secondary or backup condensate drain lineat a higher level in the condensate drain pan than the aforementionedmain condensate drain line. However, this secondary condensate drainline may also become clogged. If the air conditioner doesn't have asecondary condensate drain line, or if the secondary condensate drainline also becomes clogged, the primary condensate drain pan may fillwith condensate and at some point the condensate may begin to overflow.

In some cases, this condensate may overflow into the business orresidence and may tend to cause significant property damage. Forexample, the condensate may damage the floors, walls, carpet, andmiscellaneous other content within the business or residence. In somecases, the condensate may cause an electrical short. Sometimes suchdamage may continue to occur unnoticed for days. This tends to beexacerbated by the fact that air conditioners are often deployed inattics, closets, or other out-of-sight locations.

One approach is to have a plumber come out either from time to time orafter discovering the condensate overflow and associated damage. Theplumber typically disconnects the clogged condensate drain line, andmanually removes the microbial matter and/or debris from the condensatedrain line (for example with compressed air from a compressed air tank).Potential disadvantages of this approach are not preventing thecondensate overflow and associated damage and/or the significant costsof the plumber.

U.S. Patent Application Publication US 2006/0042292 discusses anotherapproach. As discussed in the abstract thereof, currently, there are noproducts available which allow a user to solely remove microbial andbacterial growth inside a blocked HVAC condensate drain line usingcompressed air without cutting into or disassembling the drain line. Ourvalve is an in-line condensate drain line valve that can be installedeasily, quickly and economically, either during new construction or ontoexisting HVAC systems. The HVAC user can remove microbial and bacterialgrowths without cutting into or disassembling the drain line byinjecting compressed air through the valve. The design of our valveallows the user to perform safe and routine maintenance to the HVACdrainage system without having to resort to expensive and repetitiveservice call repairs over the lifetime of the HVAC system. The valve isfurther designed to prevent undesirable reverse airflows into the HVACsystem and home or building, caused by a dry trap in the condensatedrain. The prevention of reverse airflows and reduction of microbial andbacterial growth will have a positive impact of Indoor Air Quality.

U.S. Pat. No. 6,041,611 discusses a system and method for cleaning airconditioning drains. As discussed in the abstract thereof, a system forcleaning-out a condensate drain line is disclosed. The condensate drainline is operatively associated with an air-conditioner that contains anevaporator coil and a primary drain pan. The system comprises a manifoldoperatively placed in fluid communication with the condensate drainline. The manifold includes a first, second, and third line. In oneembodiment, the first line extends from the manifold, and the second andthird line are axially aligned with the condensate drain line. Thesystem further includes a first valve member disposed within the firstline, a second valve member disposed within the second line, and a thirdvalve member disposed within the third line. A water stream, which isoperatively connected with the first line, is provided so that the waterstream may be channeled through the manifold and into the condensatedrain line. The manifold may further comprises a fourth line extendingfrom the center of the manifold, with the fourth line having a fourthvalve disposed therein. The system may further comprise sensor means,operatively associated with a secondary pan, for measuring the level ofcondensation within the secondary pan and activating an alarm once apredetermined level is reached. A method of cleaning a condensate drainline is also disclosed.

One potential drawback with all three of these approaches is that manualactions, in some cases requiring special skills or knowledge, seem to beneeded to remove the material from the condensate drain line.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention may best be understood by referring to the followingdescription and accompanying drawings that are used to illustrateembodiments of the invention. In the drawings:

FIG. 1 is a block flow diagram of an automated condensate drain linecleaning method, according to embodiments of the invention.

FIG. 2 is a block diagram of an automated condensate drain line cleaningsystem, according to embodiments of the invention.

FIG. 3A is a block diagram of a controller of an automated condensatedrain line cleaning system, the controller having cleaning timedetermination logic, according to embodiments of the invention.

FIG. 3B is a block diagram of a user input device electrically coupledwith, or otherwise in communication with, a controller of an automatedcondensate drain line cleaning system to provide user input to activatean automated cleaning, according to embodiments of the invention.

FIG. 4 is a block diagram of an automated condensate drain line cleaningsystem, according to first embodiments of the invention.

FIG. 5 is a block diagram of an automated condensate drain line cleaningsystem, according to second embodiments of the invention.

FIG. 6 is a block diagram of an automated condensate drain line cleaningsystem, according to third embodiments of the invention.

FIG. 7 is a block diagram of a vehicle having an automated condensatedrain line cleaning system, according to embodiments of the invention.

FIG. 8 is a block diagram of an automated condensate drain line cleaningkit, according to embodiments of the invention.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth.However, it is understood that embodiments of the invention may bepracticed without these specific details. In other instances, well-knowncircuits, structures and techniques have not been shown in detail inorder not to obscure the understanding of this description.

FIG. 1 is a block flow diagram of an automated condensate drain linecleaning method 100, according to embodiments of the invention.

The method includes performing an automated introduction of a fluid intothe condensate drain line, at block 102. As used herein, the term fluidmay include a liquid (e.g., water), gas (e.g., air), or a combination ofliquid and gas.

By automated it is meant that the introduction of the fluid into thecondensate drain line includes at least one device (e.g., a controller)controlling at least one other device (e.g., at least one fluid flowregulation device). For example, performing the automated introductionof the fluid may involve the controller providing at least one controlsignal to the at least one fluid flow regulation device to cause the atleast one fluid flow regulation device to introduce the fluid into thecondensate drain line. The automation implies something more than purelyhuman or manual control or actions, although it is to be understood thatsome actions or operations may be manual, such as, for example, a userpushing a button coupled with the controller or otherwise initiating theautomated introduction of the fluid.

Then, at least one of microbial material and non-microbial debris may beremoved from the condensate drain line by flowing the fluid through thecondensate drain line, at block 104. The non-microbial debris mayinclude dust, dirt, rust, or the like, or a combination thereof. By wayof example, the microbial material and/or non-microbial debris may beremoved to a sewer line, an outside location, a bucket, or othersuitable destination.

Advantageously, such a method may help to remove material from thecondensate drain line. This may help to prevent, or at least reduce, thelikelihood, of condensate overflow and its associated damage.Accordingly, this method aims to provide a preventative solution thatmay help to prevent property damage from occurring.

Furthermore, the automated introduction of a fluid into the condensatedrain line may help to reduce the involvement and/or technical knowledgerequirements of the user. Indeed, in some embodiments the level ofautomation may be such that the user may barely even need to be aware ofthe operation of the automated condensate drain line cleaning system, orthat the condensate drain pan could even overflow.

FIG. 2 is a block diagram of an automated condensate drain line cleaningsystem 210, according to embodiments of the invention.

An air conditioning system 215, a condensate drain line 220, and acondensate discharge location 225 (e.g., a sewer, outside location,bucket, or the like) are shown. These components are shown in thisfigure to illustrate the coupling of the automated condensate drain linecleaning system. However, these components are shown in dashed lines toindicate that they are generally not a part of the automated condensatedrain line cleaning system.

The automated condensate drain line cleaning system 210 includes acontroller 230, a fluid supply line 245, and at least one fluid flowregulation device 240. The controller may be implemented in hardware(e.g., a circuit or integrated circuit), software (e.g., instructionsexecutable by a general-purpose processor or computer), firmware, or acombination thereof. The controller may receive power from the airconditioning system, an outlet, a communication link, a battery, or thelike. The at least one fluid flow regulation device 240 is electricallycoupled with the controller 230 to receive at least one control signal235 from the controller 230. The at least one fluid flow regulationdevice 240 is operable to cause a fluid flow 244 into the condensatedrain line 220 through the fluid supply line 245 responsive to the atleast one control signal 235.

One specific example of a controller that is suitable, or that at leastmay be adapted for suitability, for one or more embodiments of theinvention, is the Millenium II Code 88950024 controller, which iscommercially available from Crouzet, of Coppell, Tex., USA.Alternatively, field-programmable gate arrays (FPGAs) or otheroff-the-shelf programmable controllers may optionally be used. Note thatoff-the-shelf suitable FPGAs are commercially available from varioussources and can be programmed for a specific application. There are evencompanies that can be hired to help in the programming of FPGAs forspecific applications. As another option, a general-purpose processorcapable of executing software may be used as the controller.

In the description and claims, the terms “coupled” and “connected,”along with their derivatives, may be used. It should be understood thatthese terms are not intended as synonyms for each other. Rather, inparticular embodiments, “connected” may be used to indicate that two ormore elements are in direct physical or electrical contact with eachother. “Coupled” may mean that two or more elements are in directphysical or electrical contact. However, “coupled” may also mean thattwo or more elements are not in direct contact with each other, but yetstill co-operate or interact with each other.

There are different approaches for activating or initiating theautomated condensate drain line cleaning system and method. FIG. 3Aillustrates one approach. FIG. 3B illustrates another approach.

FIG. 3A is a block diagram of a controller 330 of an automatedcondensate drain line cleaning system, according to embodiments of theinvention. The controller has a material removal time and/or cleaningtime determination logic and/or unit 350. The material removal timedetermination logic and/or unit may perform a determination or automateddetermination of a time to perform the automated introduction of thefluid into the condensate drain line.

There are literally numerous different ways in which the controller maydetermine the time to flush the drain line. To further illustratecertain concepts, a few illustrative ways will be discussed furtherbelow, although other ways will be apparent to those skilled in the artand having the benefit of the present disclosure.

In one or more embodiments of the invention, the material removal timedetermination logic and/or unit may determine the time based on at leastone of: (1) a calendar; (2) a clock; (3) a counter; (4) a sensor; and(5) information received from an external electrical device or system.Let's consider several illustrative examples of how these may be used todetermine the time.

Calendar: As one example, the controller may determine that it is timebased on the calendar day being a given day (e.g., June 21). As anotherexample, the controller may determine that it is time based on thecalendar day being a given day of the month (e.g., the first day).

Clock: As one example, the controller may determine that it is timebased on a clock counting a given amount of time since a lastintroduction of fluid into the condensate drain line. As anotherexample, the controller may determine that it is time based on a clockcounting to a given amount of air conditioner operating time since thelast introduction.

Counter: As another example, the controller may determine that it istime based on a counter counting to a given number of air conditioneron-off cycles since a last introduction.

Sensor: As another example, the controller may determine that it is timebased on a sensed level of condensate in a condensate drain pan as inputfrom a sensor. As another example, the controller may determine that itis time based on a sensed differential pressure across a filter for theair conditioner either from the sensor directly or through a thermostatthat is coupled with the actual sensor. As yet another example, thecontroller may determine that it is time based on a sensed humidityand/or outside temperature.

Information from External Device or System as input to controller: Asanother example, the controller may determine that it is time based oninformation received from a thermostat (e.g., a monitored filterdifferential pressure or filter change interval). As another example,the controller may determine that it is time based on informationreceived from a network (e.g., an internet weather station, networkedair conditioning monitoring computer system, or other networked computersystem). The controller may have, or be coupled with, a connectioninterface to the network. As yet another example, the controller maydetermine that it is time based on information received from an externalcontrol system (e.g., a home control system or control system similar tothat used to control lights in homes).

In one or more embodiments of the invention, the controller may allow auser to provide user specified configuration information that isoperable to affect how the controller determines the time. For example,the controller may allow the user to specify a calendar date, clockvalue, counter value, sensor value, or other information, which it mayuse to determine the time. The controller may also optionally allow theuser to provide a frequency factor, such as, for example, very often,often, sometimes, infrequently, and disabled, which may modulate how thecontroller determines the times. Advantageously, this may allow the userto have the automated condensate drain line cleaning system clean theline frequently, less frequently, or completely disable the automatedcondensate drain line cleaning system, depending upon time of year,environmental factors, personal preference, etc.

A few illustrative examples have been described, although the scope ofthe invention certainly is not limited to these specific examples. Thoseskilled in the art and having the benefit of the present disclosureappreciate that there are various other ways and criteria fordetermining the time. For example, the time may be determined based on acombination of the ways or criteria mentioned above. If desired,equations, calibration data, or even detailed models may optionally beused to provide additional sophistication in estimating the desired timeto clean the line.

One potential advantage of the aforementioned approach is that the userneed not be involved or need only be involved on a limited basis.However, another approach for activating or initiating the automatedcondensate drain line cleaning system and method is based on user input.This may help to simplify the logic of the controller and generally alsothe cost.

FIG. 3B is a block diagram of a user input device 360 electricallycoupled with, or otherwise in communication with, a controller 330 of anautomated condensate drain line cleaning system, according toembodiments of the invention. By way of example, the user input devicemay include at least one button, at least one switch, at least one dial,at least one knob, a touch screen, or at least one other user inputdevice known in the art. The user input device may be on a thermostat,near a thermostat, on the air conditioner (e.g., near the airconditioner filter), proximate the air conditioner, or on thecontroller, to name just a few illustrative examples.

The user input device may allow a user to activate or initiate theautomated condensate drain line cleaning system and method. For example,the automated introduction of the fluid into the condensate drain linemay be performed responsive to a user pushing at least one button,flipping at least one switch, turning at least one knob, or turning atleast one dial. Responsive to the user performing at least one of suchoperations, the user input device may provide user input 355 to thecontroller.

Such user input may cause the controller to provide at least one controlsignal to at least one fluid flow regulation device. As previouslydiscussed, this may activate or initiate the automated introduction ofthe fluid into the condensate drain line. In one or more embodiments ofthe invention, the controller may optionally have a button, switch,knob, dial, setting, or other mechanism to allow a user to disable thesystem when they don't want it to operate automatically.

One potential drawback to this approach is that the user may need toremember to initiate the cleaning. As another option, the controller maybe controlled to initiate the process by an external system, such as,for example, a thermostat, a home control system, a computer systemcoupled by a local area network (e.g., a personal computer system usedfor home control and/or monitoring), and a computer system coupledthrough the Internet (e.g., an Internet weather station and/or serverresponsible for monitoring the air conditioning system).

In one or more embodiments of the invention, the controller may includelogic to wait for at least one criteria to be satisfied before causingthe fluid to flow into the condensate drain line. In other words, afterdetermining that it is time to perform the automated introduction of thefluid into the condensate drain line, the controller may wait for atleast one criteria to be satisfied before performing the automatedintroduction of the fluid into the condensate drain line. Since thecleaning may be performed in a preventative way, instead of on an urgentneed when the problem of spillage is eminent or has already occurred,there is the possibility for delay.

Various different criteria are contemplated. For example, if thedetermined time to perform the automated introduction of the fluid islate at night (e.g., after 9:00 PM), then controller may wait untilmorning (e.g., after 9:00 AM). Advantageously, this sort of controllerintelligence may help to avoid noise during the middle of the night thatmay wake the residents.

As another example, if the determined time is during a conventional orconfigured time for eating dinner, then the controller may wait a givenamount of time (e.g., two hours) before performing the automatedintroduction of the fluid. Advantageously, this also may help to avoidnoise that may disrupt the dinner.

As yet another example, if the controller determines that the airconditioning system is currently running, then the controller may waituntil the air conditioner shuts off. This may allow the condensate drainline to remain open while condensate is being produced by the runningair conditioning system. Additionally, this may help to reduce thechances that water inside the condensate drain line may back flow intothe condensate drain pan in the event that there is a negative pressurebetween the condensate drain line discharge (e.g., at the sewer oroutside location) and the inside of the air conditioner. This delaywould provide an opportunity for the water in the condensate drain lineto drain to the sewer before the cleaning operation occurred.

In some cases, it may be appropriate for the controller to have thecapability to communicate with an external system. That system may beassociated with the cleaning process and/or monitoring of the cleaningprocess. Examples of suitable systems include, but are not limited to,thermostats, home control systems, computer systems coupled by a localarea network (e.g., a personal computer system used for home controland/or monitoring), and computer systems coupled through the Internet(e.g., an Internet weather station and/or server responsible formonitoring the air conditioning system).

In one or more embodiments of the invention, the controller may beelectrically coupled with, or otherwise in communication with, theexternal system. Furthermore, in one or more embodiments, the controllermay include logic to provide at least one signal to the external system.

The signal may provide different information in different embodiments.In one aspect, the signal may indicate that the controller just causedthe fluid to flow into the condensate drain line. In another aspect, thesignal may indicate a time when the controller will next cause the fluidto flow into the condensate drain line. In yet another aspect, thesignal may indicate both pieces of information.

As one example, the thermostat may receive and display this informationto a user so that the user may readily monitor the cleaning activity. Asanother example, the home or networked monitoring system may receive andretain this information so that the user, another person, or software,may monitor the cleaning activity.

Now, the generalized automated condensate drain line cleaning system 210of FIG. 2 may be implemented in various different ways. FIGS. 4-6provide several illustrative examples. Each of these are examples ofdifferent automated means for removing microbial buildup from said atleast the portion of the condensate drain line.

FIG. 4 is a block diagram of an automated condensate drain line cleaningsystem 410, according to first embodiments of the invention.

The automated condensate drain line cleaning system includes acontroller 430, a water supply line 445, a first water supply linecontrol valve 440, and a second control or check valve 465. As before,an air conditioning system 415, a condensate drain line 420, and acondensate discharge location 425 are shown to illustrate the couplingof the automated condensate drain line cleaning system. However, thesecomponents are shown in dashed lines to indicate that they are generallynot a part of the automated condensate drain line cleaning system. Theline coupling the controller 430 with the second control or check valve465 is dashed to indicate that it is optional, for example, it may beomitted in the case of a check valve.

The controller may be as previously described. The controller iselectrically coupled with the first water supply line control valve. Byway of example, the valve may represent any of various types ofmechanical devices capable of starting, substantially stopping,adjusting in degrees, or otherwise regulating by a movable part orportion that opens, partially opens, closes, partially closes, orpartially obstructs, a fluid passageway. In one aspect, the second valve465 may either be a control valve or a check valve. If the second valveis a control valve then it may also be electrically coupled with thecontroller (as shown by the dashed line), whereas if the second valve isa check valve it need not be electrically coupled with the controller.

The first water supply line control valve is in-line on the water supplyline. The water supply line may supply water from a sufficientlypressurized source of water. By way of example, the water supply linemay be a line, such as, for example, a section of hose or PVC pipe,leading from a standard faucet, spigot, or other source of pressurizedmunicipal or household water.

The section of the water supply line leading from the outlet of thefirst water supply line control valve is fluidically coupled with thecondensate drain line at a point 446. By way of example, the condensatedrain line may be tapped into or cut and a T-fitting inserted.Generally, that point is close to the air conditioning system, such as,for example, within a foot or several feet. This may help to promotecleaning of a majority of the condensate drain line.

In operation, the controller may provide at least one control signal 435to the first water supply line control valve in-line on the water supplyline. The at least one control signal may cause the first water supplyline control valve to at least partially open. This may cause water fromthe water supply line to flow or be introduced into the condensate drainline through the water supply line. The valve may potentially limit theflow to help to avoid damaging the condensate drain line, or asdiscussed further below a flow restriction and/or pressure reductiondevice may optionally be included. Accordingly, the first water supplyline control valve is an example of a fluid flow regulation device. Thefirst water supply line control valve may admit water to the condensatedrain line only when the controller controls it to do so.

The water introduced into the condensate drain line may have asignificantly higher flow rate than the typical flow rate of thecondensate through the line. The water may help to remove or flush atleast some of the microbial material and/or non-microbial debris fromthe condensate drain line. This may help to unclog or un-restrict thecondensate drain line. Advantageously, this may help to allow the flowof condensate from the drain pan to resume, which may advantageouslyhelp to avoid spillage and the associated property damage.

Now, it is generally desirable to prevent the water introduced throughthe water supply line from flowing into the drain pan of the airconditioning system, which could potentially result in overflow. Recallthat the automated condensate drain line cleaning system includes thesecond control or check valve 465. The second valve is in-line on thecondensate drain line and is disposed between a drain pan of the airconditioning system 415 and the point 446 where the water is introducedinto the condensate drain line from the water supply line. Generally,the second valve is close to the air conditioning system, such as, forexample, within a foot or several feet.

If the second valve is a check valve, then the check valve may allowflow in a direction leading from the air conditioning system toward thecondensate discharge location, but may prevent or at least significantlyrestrict flow in the opposite direction. Examples of suitable checkvalves include, but are not limited to, standard check valves and thevalve described in U.S. Patent Application Publication 2006/0042292.Alternatively, if the second valve is a control valve, then thecontroller may provide at least one control signal (shown in dashedlines) to the second control valve, either before or at about the sametime as the at least one control signal is provided to the first valve,to cause the second control valve to close while the water flows intothe condensate drain line. Alternatively, if there is sufficientgradient and/or if the water is introduced with sufficient velocity inthe desired direction, then the second control or check valve mayoptionally be omitted.

The cleaning process may be allowed to proceed for a sufficient amountof time, typically ranging from several seconds to several minutesdepending upon the pressures, flows, and frequency of cleaning. Afterthe cleaning process, the controller may control the first water supplycontrol valve to close to prevent further entrance of water into thecondensate drain line. The controller may then control the secondcontrol valve to open to allow flow of condensate to resume to thedischarge location. In one aspect, the controller may wait for a shortdelay, such as, for example, an the order of five seconds or more, toallow water in the condensate drain line to drain to the dischargelocation, to help ensure that it doesn't backflow into the drain pan.

FIG. 5 is a block diagram of an automated condensate drain line cleaningsystem 510, according to second embodiments of the invention.

The automated condensate drain line cleaning system includes acontroller 530, a fluid pump 540, a fluid supply line 545, and a secondcontrol or check valve 565. Also shown are an air conditioning system515, a condensate drain line 520, and a condensate discharge location525.

Unless otherwise specified or readily apparent, the components of thecondensate drain line cleaning system 510 of FIG. 5 may optionally havethe characteristics of the correspondingly named components of thecondensate drain line cleaning systems shown in FIGS. 2 and/or 4. Toavoid obscuring certain concepts, the following description will focusprimarily on the different and/or additional components and theircharacteristics.

The controller 530 is electrically coupled with the pump 540. By way ofexample, the pump may represent any of various types of mechanicaldevices capable of pumping, compressing, or otherwise enhancing thetransfer of the fluid into the condensate drain line. In variousaspects, the pump may be a gas pump (e.g., an air pump) or a liquid pump(e.g., a water pump). In the case of a water pump, the water pump may becoupled to receive input water from a condensate drain pan, a faucet orspigot, a bucket, or the like. It is to be appreciated that occasionallya liquid pump pumps a limited amount of a gas and vice versa.Accordingly, a pump is an example of a fluid flow regulation device.

In operation, at an appropriate time, the controller may provide atleast one control signal 535 to the pump. The pump may operateresponsive to the at least one control signal. In particular, the atleast one control signal may cause the pump to pump the fluid into thecondensate drain line through the fluid supply line.

As previously discussed, the fluid may help to remove or flush at leastsome of the microbial material and/or non-microbial debris from thecondensate drain line. This may help to unclog or un-restrict thecondensate drain line. Advantageously, this may help to allow the flowof condensate from the drain pan to resume, which may advantageouslyhelp to avoid spillage and the associated property damage.

In one or more embodiments of the invention, a fluid accumulation tank,such as for example, a pressurized cylinder, may be coupled with thedischarge of the pump to accumulate or store fluid for later releaseinto the condensate drain line. While this generally offers greateradvantages for gases, it may be used for liquids if desired.

FIG. 6 is a block diagram of an automated condensate drain line cleaningsystem 610, according to third embodiments of the invention.

The automated condensate drain line cleaning system includes acontroller 630, an air pump 640, an air storage tank 642, an air supplyline 645, and a second control or check valve 665. Also shown are an airconditioning system 615, a condensate drain line 620, and a condensatedischarge location 625.

Unless otherwise specified or readily apparent, the components of thecondensate drain line cleaning system 610 of FIG. 6 may optionally havethe characteristics of the correspondingly named components of thecondensate drain line cleaning systems shown in FIGS. 2 and/or 4-5. Toavoid obscuring certain concepts, the following description will focusprimarily on the different and/or additional components and theircharacteristics.

The controller 630 is electrically coupled with the air pump 640. Inoperation, at an appropriate time, the controller may provide at leastone control signal 635 to the air pump. Various known types of air pumpsare suitable including fans, blowers, and compressors. The air pump mayoperate responsive to the at least one control signal. In particular,the at least one control signal may cause the air pump to pump air intothe air storage tank.

The air storage tank is coupled between the air pump and the condensatedrain line. The air storage tank may accumulate and store the air. Byway of example, the air storage tank may have a capacity ranging fromabout half a quart to about a gallon, or more, although this is notrequired. The air storage tank may include a pressurized cylinder orother pressure vessel. The pressure in the air storage tank may increaseover time as more air is pumped into the air storage tank.

At some point, the controller may control the air pump to stop pumpingair into the air storage tank. When it is time to clean the condensateline, the controller may control the air storage tank to discharge thestored and pressurized air into the condensate drain line. Thispressurized air may help to clean the condensate drain line.

One potential advantage of the air pump and air storage tank is thatthey may be well suited for retrofitting an existing air conditioningsystem. There is no need to run a separate water supply line.Additionally, one potential advantage of the air storage tank is to helpto allow a smaller and less expensive air pump to be used than would beneeded if the air storage tank were not there. Alternatively, the airpump may be used without the air storage tank, or a pre-compressed airtank may optionally be used.

Since the flow through condensate drain lines is generally relativelylow, the condensate drain lines and their couplings are not alwaysdesigned to handle appreciable pressures and/or fluid flow rates. Insome cases, it is contemplated that the fluid introduced into thecondensate drain line by the automated condensate drain line cleaningsystem may have sufficient pressure and/or flow that it may potentiallydamage the condensate drain line, its couplings, and/or one or moreother components downstream.

In one or more embodiments of the invention, the automated condensatedrain line cleaning system, such as, for example, that shown in FIG. 2,4, 5, 6, or 7 may include an optional flow restriction and/or pressurereduction device. The flow restriction and/or pressure reduction devicemay be operable to reduce the flow rate and/or the pressure of the fluidintroduced into the condensate drain line and may be operable to preventthe fluid from damaging the condensate drain line or another componentdownstream from the flow restriction and/or pressure reduction device.

Examples of suitable flow restriction and/or pressure reduction devicesinclude, but are not limited to, relatively small or constrictionorifices, relatively small or constriction valves, relatively small orconstriction sections of piping or line, constriction bends, and otherrelatively small and/or constriction devices and structures. These mayeither be incorporated into an existing flow regulation device (e.g., asolenoid or control valve) or may be separate. Examples of a suitablesolenoid valves include those available from Gems Sensors & Controls, ofPlainville, Conn., USA, some of which have a built in orifice. Such flowrestriction and/or pressure reduction devices may be used with variousof the automated condensate drain line cleaning systems disclosedherein.

In one or more embodiments of the invention, the automated condensatedrain line cleaning system, such as, for example, that shown in FIG. 2,4, 5, 6, or 7 may include an optional pressure sensor. Examples ofsuitable pressure sensors include, but are not limited to, smallpiezoelectric sensors. By way of example, the pressure sensor may befluidically coupled after the fluid flow regulation device 240, firstcontrol valve 440, fluid pump 540, air storage tank 642. If an optionalflow restriction and/or pressure reduction device is included, then thepressure sensor may optionally be after it. The pressure sensor may beelectrically or logically coupled with, or in communication with, thecontroller to provide a sensed pressure to the controller. Thecontroller may control the control valve, pump, or other controlleddevice based at least in part on the sensed pressure. In one aspect, thecontroller may use the sensed pressure as feedback to control the valve,pump, or other controlled device. As one example, the controller mayadjust the valve, pump, or other controlled device, based on the sensedpressure to help to achieve a predetermined, given, or sufficientpressure. For example, the controller may further open the valve orincrease the output of the pump if the sensed pressure is too low (e.g.,lower than a threshold). Advantageously, this may help to improvecleaning. As another example, the controller may at least partiallyclose the valve or at least partially reduce the output of the pump ifthe sensed pressure is too high (e.g., higher than a threshold), whichmay potentially indicate that the discharge line is blocked. Thecontroller may also potentially interrupt the cleaning operations and/orissue an alarm (e.g., a piezoelectric warning buzzer) so that correctiveactions may be taken. Advantageously, this may help to avoid systemdamage and/or leakage.

The utility of the automated condensate drain line cleaning systems andmethods disclosed herein are not limited to use in home or business airconditioning systems but are more widely applicable to otherenvironments having air conditioning systems. One notable example is invehicles.

FIG. 7 is a block diagram of a vehicle 770 having an automatedcondensate drain line cleaning system 710, according to embodiments ofthe invention.

By way of example, the vehicle may be a car, a truck, a motorcycle,industrial vehicle (e.g., dump truck or garbage truck), airplane, tank,or the like. The vehicle has an onboard air compressor and a condensatedrain line. These components are shown in dashed lines to indicate thatthey are not necessarily part of the automated condensate drain linecleaning system. Rather, these components may be conventional componentsfound in vehicles.

The automated condensate drain line cleaning system includes acontroller 730 and at least one fluid flow regulation device 740, suchas, for example, a control valve. The automated condensate drain linecleaning system is coupled with and/or attached to the vehicle.

The fluid flow regulation device is coupled to allow compressed air fromthe onboard air compressor of the vehicle to flow or be introduced intothe condensate drain line through a fluid supply line responsive to atleast one control signal from the controller. In particular, the fluidflow regulation device has an input that is fluidically coupled with anoutput of the onboard air compressor. An output of the fluid flowregulation device is fluidically coupled with the condensate drain linethrough a fluid supply line 745. The controller is electrically coupledwith the fluid flow regulation device to provide the at least onecontrol signal 735 to cause the automated introduction of the compressedair. The controller may be electrically coupled with the electricalsystem of the vehicle, or it may have its own battery, to name a fewexamples.

In embodiments of the invention, the automated condensate drain linecleaning systems disclosed herein may be assembled or incorporated withnew air conditioning systems in factories. It is hoped and believed thatthe automated condensate drain line cleaning systems disclosed hereinwill provide new functionalities that may help to encourage the sale ofthe air conditioning systems that incorporate them.

As another option, in other embodiments of the invention, components ofthe automated condensate drain line cleaning systems disclosed hereinmay be sold in various combinations as kits that may be installed onand/or used to retrofit a new and/or existing air conditioning system.

FIG. 8 is a block diagram of an automated condensate drain line cleaningkit 880, according to embodiments of the invention.

The kit includes a controller 830, at least one fluid flow regulationdevice 840, and instructions 885. The controllers and fluid flowregulation devices discussed elsewhere herein are suitable. The at leastone fluid flow regulation device, such as, for example, one or morevalves and/or pumps, may be capable of being electrically coupled withthe controller.

The instructions may be paper instructions and/or instructions stored ona computer disk, compact disk, DVD, or other machine-readable medium.The instructions may explain how to assemble the kit to an airconditioning system and/or how to use the automated condensate drainline cleaning kit and system. By way of example, the instructions mayinclude instructions to electrically couple the controller with the atleast one fluid flow regulation device. The instructions may alsoinclude instructions to couple the at least one fluid flow regulationdevice with a condensate drain line through a path including a fluidsupply line and potentially other components (e.g., in some cases afluid storage tank). With this coupling, the at least one fluid flowregulation device may be operable to cause a fluid to flow into thecondensate drain line responsive to at least one control signal receivedfrom the controller.

Referring again to FIG. 8, in one or more embodiments, the kit mayinclude at least one other component 890. Examples of suitable othercomponents include, but are not limited to, a fluid storage tank, an airstorage tank, a flow restriction device, at least one user input device,a condensate drain line, an amount of a known antimicrobial agent to beapplied to the condensate drain line, and combinations thereof.

In the description above, for the purposes of explanation, numerousspecific details have been set forth in order to provide a thoroughunderstanding of the embodiments of the invention. It will be apparenthowever, to one skilled in the art, that one or more other embodimentsmay be practiced without some of these specific details. The particularembodiments described are not provided to limit the invention but toillustrate it. The scope of the invention is not to be determined by thespecific examples provided above but only by the claims below. In otherinstances, well-known circuits, structures, devices, and operations havebeen shown in block diagram form or without detail in order to avoidobscuring the understanding of the description. All equivalentrelationships to those illustrated in the drawings and described in thespecification are encompassed within embodiments of the invention.

Various operations and methods have been described. Some of the methodshave been described in a basic form, but operations may optionally beadded to and/or removed from the methods. The operations of the methodsmay also often optionally be performed in different order. Manymodifications and adaptations may be made to the methods and arecontemplated.

Certain operations may be performed by hardware components, or may beembodied in machine-executable instructions, that may be used to cause,or at least result in, a circuit programmed with the instructionsperforming the operations. The circuit may include a general-purpose orspecial-purpose processor, or logic circuit, to name just a fewexamples. The operations may also optionally be performed by acombination of hardware and software.

One or more embodiments of the invention may be provided as a programproduct or other article of manufacture that may include amachine-accessible and/or readable medium having stored thereon one ormore instructions and/or data structures. The medium may provideinstructions, which, if executed by a machine, may result in and/orcause the machine to perform one or more of the operations or methodsdisclosed herein.

For clarity, in the claims, any element that does not explicitly state“means for” performing a specified function, or “step for” performing aspecified function, is not to be interpreted as a “means” or “step”clause as specified in 35 U.S.C. Section 112, Paragraph 6. Inparticular, any potential use of “step of” in the claims herein is notintended to invoke the provisions of 35 U.S.C. Section 112, Paragraph 6.

It should also be appreciated that reference throughout thisspecification to “one embodiment”, “an embodiment”, or “one or moreembodiments”, for example, means that a particular feature may beincluded in the practice of the invention. Similarly, it should beappreciated that in the description various features are sometimesgrouped together in a single embodiment, Figure, or description thereoffor the purpose of streamlining the disclosure and aiding in theunderstanding of various inventive aspects. This method of disclosure,however, is not to be interpreted as reflecting an intention that theinvention requires more features than are expressly recited in eachclaim. Rather, as the following claims reflect, inventive aspects maylie in less than all features of a single disclosed embodiment. Thus,the claims following the Detailed Description are hereby expresslyincorporated into this Detailed Description, with each claim standing onits own as a separate embodiment of the invention.

What is claimed is:
 1. A method comprising: performing an automatedintroduction of a fluid into a condensate drain line; and removing atleast one of microbial material and non-microbial debris from thecondensate drain line by flowing the fluid through the condensate drainline.
 2. The method of claim 1, wherein performing the automatedintroduction of the fluid into the condensate drain line comprisesproviding at least one control signal to at least one fluid flowregulation device.
 3. The method of claim 2, wherein providing the atleast one control signal to the at least one fluid flow regulationdevice comprises providing at least one control signal to a firstcontrol valve to cause the first control valve to at least partiallyopen to introduce the fluid into the condensate drain line.
 4. Themethod of claim 3, wherein providing the at least one control signal tothe first control valve comprises providing the at least one controlsignal to a water supply control valve that is in-line on a water supplyline to cause the water supply control valve to at least partially opento introduce water into the condensate drain line.
 5. The method ofclaim 4, wherein introducing the water into the condensate drain linecomprises flowing the water through a flow restriction device that isoperable to prevent the water from the water supply line from damaging acomponent downstream from the flow restriction device.
 6. The method ofclaim 3, wherein providing the at least one control signal to the atleast one fluid flow regulation device comprises providing at least onecontrol signal to a second control valve, which is in-line on thecondensate drain line, and which is between a drain pan and a pointwhere the fluid is introduced into the condensate drain line, to causethe second control valve to close.
 7. The method of claim 2, whereinproviding the at least one control signal to the at least one fluid flowregulation device comprises providing at least one control signal to apump to cause the pump to pump the fluid into one selected from thecondensate drain line and an optional storage tank coupled between thepump and the condensate drain line.
 8. The method of claim 7, whereinproviding the at least one control signal to the pump comprisesproviding the at least one control signal to a water pump.
 9. The methodof claim 7, wherein providing the at least one control signal to thepump comprises providing the at least one control signal to an air pumpto cause the air pump to pump air into an air storage tank coupledbetween the air pump and the condensate drain line.
 10. The method ofclaim 1, further comprising performing an automated determination of atime to perform the automated introduction of the fluid into thecondensate drain line.
 11. The method of claim 10, wherein performingthe automated determination of the time comprises a controllerdetermining the time based on at least one of: a calendar; a clock; acounter; a sensor; information received from an external electricalsystem.
 12. The method of claim 11, wherein the controller determinesthe time based on at least one of: a calendar date; an amount of timesince a last automated introduction of a fluid into the condensate drainline; an amount of air conditioner operating time since the lastautomated introduction of the fluid into the condensate drain line; aduty cycle since the last automated introduction of the fluid into thecondensate drain line; a number of air conditioning on-off cycles sincethe last automated introduction of the fluid into the condensate drainline; a sensed level of condensate in a condensate drain pan; a senseddifferential pressure across a filter for the air conditioner; at leastone sensed humidity; information received from a thermostat; informationreceived from a network; information received from an external controlsystem; and user specified configuration information operable to affectthe determined time.
 13. The method of claim 1, further comprising:determining that it is time to perform the automated introduction of thefluid into the condensate drain line; and waiting for at least onecriteria to be satisfied before performing the automated introduction ofthe fluid into the condensate drain line.
 14. The method of claim 1,wherein the method is implemented in a vehicle, and wherein performingthe automated introduction of the fluid into the condensate drain linecomprises performing an automated introduction of compressed air from anonboard air compressor of the vehicle into the condensate drain line.15. The method of claim 1, further comprising providing at least onesignal to an external system that is selected from a thermostat, a homecontrol system, a computer system coupled by a local area network, and acomputer system coupled through the Internet, wherein the at least onesignal is operable to indicate at least one of: (1) that the automatedintroduction of the fluid into the condensate drain line was justperformed; and (2) a time when a next automated introduction of a fluidinto the condensate drain line will be performed.
 16. The method ofclaim 1, wherein the automated introduction of the fluid into thecondensate drain line is performed responsive to a user performing atleast one of: pushing at least one button; flipping at least one switch;turning at least one knob; turning at least one dial; and touching atouch screen.
 17. An apparatus comprising: a controller; a fluid supplyline; and at least one fluid flow regulation device electrically coupledwith the controller to receive at least one control signal from thecontroller, the at least one fluid flow regulation device to cause afluid to flow into a condensate drain line through the fluid supply lineresponsive to the at least one control signal.
 18. The apparatus ofclaim 17, wherein the at least one fluid flow regulation devicecomprises at least one of a control valve and a pump.
 19. The apparatusof claim 18: wherein the fluid supply line comprises a water supplyline; and wherein the at least one fluid flow regulation devicecomprises a first water supply control valve in-line on the water supplyline, the first water supply control valve to at least partially openresponsive to the at least one control signal to cause water from thewater supply line to flow into the condensate drain line.
 20. Theapparatus of claim 19, further comprising a flow restriction devicecoupled with the water supply line and that is operable to prevent thewater from the water supply line from damaging a component downstreamfrom the flow restriction device.
 21. The apparatus of claim 18, whereinthe at least one fluid flow regulation device comprises a pump to pumpthe fluid into one selected from the condensate drain line through thefluid supply line and an optional storage tank coupled between the pumpand the condensate drain line, responsive to the at least one controlsignal.
 22. The apparatus of claim 21: wherein the fluid supply linecomprises an air supply line; and wherein the pump comprises an air pumpto pump air into an air storage tank coupled between the air pump andthe condensate drain line.
 23. The apparatus of claim 17, wherein thecontroller comprises logic to determine a time to provide the at leastone control signal to the at least one fluid flow regulation device. 24.The apparatus of claim 23, wherein the controller is to determine thetime based on input from at least one of a calendar of the controller, aclock of the controller, a counter of the controller, a sensor, andinformation received from an external electrical system coupled with thecontroller.
 25. The apparatus of claim 17, wherein the controllercomprises logic to wait for at least one criteria to be satisfied beforecausing the fluid to flow into the condensate drain line.
 26. Theapparatus of claim 17, wherein the controller comprises logic to provideat least one signal to an external system that is selected from athermostat, a home control system, a computer system coupled by a localarea network, and a computer system coupled through the Internet,wherein the at least one signal is operable to indicate at least one of:(1) that the controller just caused the fluid to flow into thecondensate drain line; and (2) a time when the controller will nextcause the fluid to flow into the condensate drain line.
 27. Theapparatus of claim 17, wherein the controller receives power from an airconditioning unit.
 28. The apparatus of claim 17, wherein the apparatusis attached to a vehicle, and wherein the at least one fluid flowregulation device is coupled to allow compressed air from an onboard aircompressor of the vehicle to flow into the condensate drain line throughthe fluid supply line responsive to the at least one control signal. 29.The apparatus of claim 17, further comprising an anti-microbial surfacecoating on an inside surface of the condensate drain line.
 30. Theapparatus of claim 17, further comprising a user input deviceelectrically coupled with the controller to allow a user to cause thecontroller to provide the at least one control signal to the at leastone fluid flow regulation device.
 31. A kit comprising: a controller; atleast one fluid flow regulation device capable of being electricallycoupled with the controller; instructions to couple the at least onefluid flow regulation device with a condensate drain line through a pathincluding a fluid supply line so that the at least one fluid flowregulation device is operable to cause a fluid to flow into thecondensate drain line responsive to at least one control signal receivedfrom the controller.
 32. The kit of claim 31, wherein the at least onefluid flow regulation device comprises a control valve.
 33. The kit ofclaim 31, wherein the at least one fluid flow regulation devicecomprises a pump.
 34. The kit of claim 33, wherein the pump comprises anair pump, wherein the kit further comprises an air storage tank, andwherein the instructions comprise instructions to couple the air storagetank between the air pump and the condensate drain line.
 35. The kit ofclaim 31, further comprising a flow restriction device, and wherein theinstructions comprise instructions to couple the flow restriction devicein the path.
 36. The kit of claim 31, wherein the controller compriseslogic to determine a time to provide the at least one control signal tothe at least one fluid flow regulation device.
 37. The kit of claim 31,wherein the controller comprises logic to wait for at least one criteriato be satisfied before causing the fluid to flow into the condensatedrain line.
 38. The kit of claim 31, further comprising at least oneuser input device selected from at least one button, at least oneswitch, at least one knob, and at least one dial, and wherein the atleast one user input device is operable to be electrically coupled withthe controller to allow a user to control when the controller providesthe at least one control signal to the at least one fluid flowregulation device.
 39. The kit of claim 31, wherein the controllercomprises logic to provide at least one signal to an external systemthat is selected from a thermostat, a home control system, a computersystem coupled by a local area network, and a computer system coupledthrough the Internet, wherein the at least one signal is operable toindicate at least one of: (1) that the controller just caused the fluidto flow into the condensate drain line; and (2) a time when thecontroller will next cause the fluid to flow into the condensate drainline.
 40. The kit of claim 31, further comprising an antimicrobial agentto be applied to the condensate drain line.
 41. An apparatus comprising:at least a portion of a condensate drain line; and automated means forremoving microbial buildup from said at least the portion of thecondensate drain line.
 42. The apparatus of claim 41, wherein theautomated means comprises a controller.
 43. The apparatus of claim 42,wherein the automated means comprises at least one fluid flow regulationdevice electrically coupled with the controller to receive at least onecontrol signal from the controller.
 44. The method of claim 2, furthercomprising sensing a pressure, and wherein the at least one controlsignal provided to the at least one fluid flow regulation device isbased at least in part on the sensed pressure.
 45. The apparatus ofclaim 17, further comprising a pressure sensor in communication with thecontroller, and coupled to sense a pressure of the fluid from the atleast one fluid flow regulation device, wherein the controller is tocontrol the at least one fluid flow regulation device based, at least inpart, on the sensed pressure.